Forming structures from cad solid models

Abstract

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure ( ) is disclosed. The invention enables the control of material characteristics, within a structure ( ) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head ( ) in a directed material deposition process ( ). Material feedstock ( ) is deposited onto a pre-heated substrate ( ). Depositions ( ) in a layer-by-layer pattern, defined by solid models ( ), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles ( ), not available through conventional processing techniques, is enabled by embedded voids ( ) and/or composite materials ( ), which include dissimilar metals ( ). Finished articles control pressure drop and produce uniform coolant flow and pressure characteristics. High-efficiency heat transfer is engineered within a solid structure by incorporating other solid materials with diverse indexes. Embedding multi-material structures ( ) within a normally solid component ( ) produces articles with diverse mechanical properties. Laser and powder delivery systems ( ) are integrated in a multi-axis deposition head ( ) having a focused particle beam ( ) to reduce material waste.